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SAFETYOperation and Maintenance Manual Excerpt

SEBU7501-03June 2004

Operation andMaintenanceManual533 and 543 Wheel Feller BunchersASJ1-Up (Machine)CDR1-Up (Machine)

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Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

6Safety SectionSafety Messages

Safety Sectioni02117263

Safety MessagesSMCS Code: 7000

g01080702Illustration 2

7Safety Section

Safety Messages


There are several specific safety signs on thismachine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all safetysigns.

Make sure that all of the safety signs are legible.Clean the safety signs or replace the safety signs ifyou cannot read the words. Replace the illustrationsif the illustrations are not legible. When you clean thesafety signs, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the safety signs. Solvents, gasoline, or harshchemicals could loosen the adhesive that securesthe safety sign. Loose adhesive will allow the safetysign to fall.

Replace any safety sign that is damaged or missing.If a safety sign is attached to a part that is replaced,install a safety sign on the replacement part. Anyyour dealer can provide new safety signs.


Do Not Operate the Machine (1)This warning is located on the right side window inthe cab.

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Do not operate or work on this machine unlessyou have read and understand the instructionsand warnings in the Operation and Maintenancemanuals. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact your authorized dealer for replacement man-uals. Proper care is your responsibility.

Do Not Add Ether (2)This warning is located on the cover of the engineair cleaner.

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Explosion hazard! Do not use ether! This machineis equipped with an air inlet heater. Using ethercan create explosions or fires that can cause per-sonal injury or death. Read and follow the startingprocedure in the Operation and Maintenance Man-ual.

Electrical Shock Hazard (3)This warning is located on the right side window inthe cab.

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Know the maximum height and reach of your ma-chine.

Serious injury or death by electrocution can occurif machine or attachments are not kept a safe dis-tance from electrical power lines. Keep distanceat least 3 m (10 ft) plus additional 10 mm (0.4 inch)for each 1,000 volts over 50,000 volts.

9Safety Section

Safety Messages

Flying Debris (4)These warnings are located on the left side and onthe right side of the machine.

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Sawhead discharge debris may be increasedin rough or hilly terrain. Heavier debris has thepotential to travel greater distances. Always beaware of the flight angle of the sawhead dis-charge.

Avoid cutting when people, domestic animals,building or personal property are located on thedischarge side of the saw. Reposition the disc sawas necessary to avoid possible damage causedby the saw discharge.

All personnel should be more than 91 m (300 ft) awayfrom the machine before the machine is started.Maintain a distance of 91 m (300 ft) in all directionsduring the operation of the machine.

Moving Parts and Flying Debris (5)This danger label is located on the outside of the liftarms near the connection point.

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The operation of the machine can cause debris tofly. Stay clear of rotating blades and moving partsduring machine operation. Stop the rotation of thecutting gear before approaching the machine. Theflying debris, moving parts and/or rotating bladescan cause serious injury or death.

Stay clear of the felling head while the machine isoperating. Before you service the felling head, lowerthe felling head and turn off the machine.


No Clearance (6)This warning is located near the articulation joint onboth sides of the front frame.

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No clearance for person in this area whenmachineturns. Severe injury or death from crushing couldoccur.

“Connect the steering frame lock between the frontand the rear frames before lifting, transporting, orservicing the machine in the articulation area.”

“Disconnect the steering frame lock and secure thesteering frame lock before resuming operation.”

Battery (7)This warning is located at the rear right side of themachine near the auxiliary start receptacle and at therear left side of the machine on the battery door.

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There is limited battery access. Jump starting atthe battery, or improper jumper cable connectionsat the starter, can cause explosion resulting in per-sonal injury.

Do not jump start the machine at the battery. Usethe remote starting receptacle or jump start to thepositive battery post on the starter.

If remote starting receptacle can not be used,jumper cables may be used at the starter. Alwaysconnect the positive (+) cable to positive (+) termi-nal of the starter and connect negative (−) cablefrom external source to engine block. Followprocedure from the Operation and MaintenanceManual.

Before any service to the batteries, or starting theengine with an auxiliary starting plug, read theService Manual. Refer to Operation and MaintenanceManual, “Engine Starting with Auxiliary StartReceptacle (If Equipped), Battery - Clean, BatteryHold-Down - Tighten, Battery or Battery Cable -Inspect/Replace”.

11Safety Section

Safety Messages

ROPS/FOPS Structure (8)This warning label is located on the left side of therear crossbar inside the cab.

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Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-ture’s protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. Consult a Caterpillar dealer to deter-mine this structure’s limitations without voidingits certification.

Personal injury or death can result when voidingthis certification.

Structural damage, an overturn, modification, al-teration, or improper repair can impair the ROPSstructure’s protection capability thereby voidingthis certification.

Do not weld on or drill holes in the structure.

To avoid possible weakening of this ROPs, con-sult your authorized dealer before altering thisROPS in any way. The protection offered by thisROPS will be impaired if it has been subjected tostructural damage

Consult your authorized dealer in order to deter-mine this structures’s limitations without voidingits certification.

This machine has been certified to the standards thatare listed on the certification plate. The maximummass of the machine, which includes the operatorand the attachments without a payload, should notexceed the mass on the certification plate.

Crushing (9)This warning is located on both sides of the lift armsnear the connection point.

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Before you service the machine or the attachments,lower the attachments to the ground. Also, turn offthe power. Refer to the Operation and MaintenanceManual for more information.

Engine Coolant Under Pressure(10)The warning label is located on the inside surface ofthe radiator cap cover and on the coolant recoverybottle on the right side of the machine.

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Pressurized System: Hot coolant can cause se-rious burns. To open the cooling system fillercap, stop the engine and wait until the coolingsystem components are cool. Loosen the coolingsystem pressure cap slowly in order to relieve thepressure. Read and understand the Operation andMaintenance manual before performing coolingsystem maintenance.


Hydraulic System Under Pressure(11)This warning is located at the rear of the machine onthe hydraulic tank near the sight gauge.

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Personal injury can result from removing hoses orfittings in a system under pressure.

Failure to relieve pressure can cause personal in-jury.

Do not remove or disconnect hoses or fittings un-til all pressure in the hydraulic system has beenrelieved.

Hydraulic line may be under pressure. Refer to theOperation and Maintenance Manual for any proce-dures that are required to relieve hydraulic pres-sure before disassembly. Failure to do so couldresult in personal injury.

Brake Accumulator Pressure (12)This warning is located on the bracket for the brakeaccumulator underneath the cab.

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Escaping fluid under pressure, even a pinhole sizeleak, can penetrate body tissue, causing seriousinjury, and possible death. If fluid is injected intoyour skin, it must be treated immediately by a doc-tor familiar with this type of injury.

Always use a board or cardboard when checkingfor a leak.

Hydraulic line may be under pressure. Refer to theOperation and Maintenance Manual for any proce-dures that are required to relieve hydraulic pres-sure before disassembly. Failure to do so couldresult in personal injury.

Before any service to the service brakes, purgethe braking pressure. Refer to the Service ManualTesting and Adjusting, RENR6159, “Service BrakeSystem Pressure - Test”.

13Safety Section

Additional Messages

Water Cleaning System UnderPressure (13)This warning label is located near the filler plug onthe water tank at the rear of the machine.

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Do not remove the fill plug until the pressure in thewater tank has been relieved. Personal injury mayresult.

This fill plug has a cross drilled hole that allowsthe pressure to be relieved without disengagingthe threads.

Do not replace this fill plug with any other plug.

For more information, refer to Operation andMaintenance Manual, “Water Cleaning System”.

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Additional MessagesSMCS Code: 7000

There are several specific messages on thismachine. The exact location of the messages andthe description of the messages are reviewed inthis section. Please become familiarized with allmessages.

Make sure that all of the messages are legible.Clean the messages or replace the messages ifyou cannot read the words. Replace the illustrationsif the illustrations are not legible. When you cleanthe messages, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures themessages. Loose adhesive will allow the messagesto fall.

Replace any message that is damaged, or missing.If a message is attached to a part that is replaced,install a message on the replacement part. Anyauthorized dealer can provide new messages.



14Safety SectionAdditional Messages

Air Conditioner (1)


This message is located on the compressor for theair conditioner. Read the service manual before youperform any maintenance on the air conditioner.

Pressurize The Water CleaningSystem (2)


This message is located on the left side of theoperator’s seat.

Reference: For additional information, refer to theOperation and Maintenance Manual, “Water CleaningSystem (Pressurized) - Purge”.

Shipping Instruction (3)


This message is located on the left side of themachine at the articulation joint.

Reference: For more information on shipping, referto Operation and Maintenance Manual, “Shipping theMachine” and Operation and Maintenance Manual,“Lifting and Tying Down the Machine”.

Machine Voltage (4)


This message is located on the right side of themachine at the auxiliary start receptacle.

The message gives the proper voltage for themachine.

15Safety Section

General Hazard Information

Cleaning Windows (5)


This message is located on the right door inside thecab.

For additional information about cleaning thewindows, refer to the Service Manual Operations andMaintenance Manual, “Windows - Clean”.

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General Hazard InformationSMCS Code: 7000


Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment. These warning tags (SpecialInstruction, SEHS7332) are available from yourCaterpillar dealer.

Know the width of your equipment in order to maintainproper clearance when you operate the equipmentnear fences or near boundary obstacles.

Be aware of high voltage power lines and powercables that are buried. If the machine comes incontact with these hazards, serious injury or deathmay occur from electrocution.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the equipment.

Make sure that all protective guards and all coversare secured in place on the equipment.

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools,and other items that are not a part of the equipment.

Know the appropriate work site hand signals andthe personnel that are authorized to give the handsignals. Accept hand signals from one person only.

Do not smoke when you service an air conditioner.Also, do not smoke if refrigerant gas may be present.Inhaling the fumes that are released from a flame thatcontacts air conditioner refrigerant can cause bodilyharm or death. Inhaling gas from air conditionerrefrigerant through a lighted cigarette can causebodily harm or death.

Never put maintenance fluids into glass containers.Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report allnecessary repairs.

Do not allow unauthorized personnel on theequipment.

16Safety SectionGeneral Hazard Information

Unless you are instructed otherwise, performmaintenance with the equipment in the servicingposition. Refer to Operation and Maintenance Manualfor the procedure for placing the equipment in theservicing position.

Pressure Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressure air and/or pressure water is used forcleaning, wear protective clothing, protective shoes,and eye protection. Eye protection includes gogglesor a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (50 psi).

Trapped PressurePressure can be trapped in a hydraulic system.Accumulators in a hydraulic system will storepressure. Allow a sufficient amount of time forthe pressure that is stored in the accumulatorsto be released. Releasing trapped pressure cancause sudden machine movement or attachmentmovement. Use caution if you disconnect hydrauliclines or fittings. High pressure oil that is releasedcan cause a hose to whip. High pressure oil that isreleased can cause oil to spray. Fluid penetration cancause serious injury and possible death.

Fluid PenetrationPressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the ServiceManual for any procedures that are required torelieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theequipment. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component containing fluids.

Refer to Special Publication, NENG2500, “Tools andShop Products Guide” for the following items:

• Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

17Safety Section

Crushing Prevention and Cutting Prevention

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machiningjobs.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

• Stay away from areas that might have asbestosparticles in the air.

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

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Crushing Prevention andCutting PreventionSMCS Code: 7000

Support the equipment properly before you performany work or maintenance beneath that equipment.Do not depend on the hydraulic cylinders to holdup the equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

Do not work beneath the cab of the machine unlessthe cab is properly supported.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving or whilethe engine is running.

18Safety SectionBurn Prevention

Never jump across the starter solenoid terminalsin order to start the engine. Unexpected machinemovement could result.

Whenever there are equipment control linkages theclearance in the linkage area will change with themovement of the equipment or the machine. Stayclear of areas that may have a sudden change inclearance with machine movement or equipmentmovement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to performmaintenance, always install the guards after themaintenance is performed.

Keep objects away from moving fan blades. The fanblade will throw objects or cut objects.

Do not use a kinked wire cable or a frayed wire cable.Wear gloves when you handle wire cable.

When you strike a retainer pin with force, the retainerpin can fly out. The loose retainer pin can injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin. To avoid injury toyour eyes, wear protective glasses when you strikea retainer pin.

Chips or other debris can fly off an object when youstrike the object. Make sure that no one can beinjured by flying debris before striking any object.

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Burn PreventionSMCS Code: 7000

Do not touch any part of an operating engine.Allow the engine to cool before any maintenance isperformed on the engine. Relieve all pressure in theair system, in the oil system, in the lubrication system,in the fuel system, or in the cooling system beforeany lines, fittings or related items are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level only after the engine hasbeen stopped.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot components can cause personalinjury. Do not allow hot oil to contact the skin. Also,do not allow hot components to contact the skin.

Remove the hydraulic tank filler cap only after theengine has been stopped. The filler cap must becool enough to touch with a bare hand. Follow thestandard procedure in this manual in order to removethe hydraulic tank filler cap.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

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Fire Prevention and ExplosionPreventionSMCS Code: 7000


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

19Safety Section

Fire Prevention and Explosion Prevention

Remove all flammable materials such as fuel, oil, anddebris from the machine. Do not allow any flammablematerials to accumulate on the machine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not operate the machine near any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil spray or fuel spray in case ofa break in a line, in a hose, or in a seal. Exhaustshields must be installed correctly.

Do not weld on lines or on tanks that containflammable fluids. Do not flame cut lines or tanksthat contain flammable fluid. Clean any such lines ortanks thoroughly with a nonflammable solvent priorto welding or flame cutting.

Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate themachine. Clean all electrical connections and tightenall electrical connections.

Dust that is generated from repairing nonmetallichoods or nonmetallic fenders can be flammableand/or explosive. Repair such components in a wellventilated area away from open flames or sparks.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and the hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.


Use caution when you are refueling a machine. Donot smoke while you are refueling a machine. Donot refuel a machine near open flames or sparks.Always stop the engine before refueling. Fill the fueltank outdoors.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

EtherEther is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

20Safety SectionFire Extinguisher Location

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperaturesabove 49 °C (120 °F). Keep ether cylinders awayfrom open flames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the machine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During machine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

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Fire Extinguisher LocationSMCS Code: 7000


The recommended location for mounting the fireextinguisher is on the right side of the cab above therear window.

Make sure that a fire extinguisher is on the machine.Make sure that you are familiar with the operation ofthe fire extinguisher. Inspect the fire extinguisher andservice the fire extinguisher on a regular basis. Obeythe recommendations on the instruction plate.

If the fire extinguisher is mounted on the ROPS, strapthe mounting plate to a leg of the ROPS. If the weightof the fire extinguisher is more than 4.5 kg (10 lb),mount the fire extinguisher as low as possible on oneleg. Do not mount the fire extinguisher on the upperone-third area of the leg.

Note: Do not weld the ROPS in order to install thefire extinguisher. Also, do not drill holes in the ROPSin order to mount the fire extinguisher on the ROPS.

i01676089

Tire InformationSMCS Code: 7000

Explosions of air inflated tires have resulted fromheat-induced gas combustion inside the tires.Explosions can be caused by heat that is generatedby welding, by heating rim components, by externalfire, or by excessive use of brakes.

A tire explosion is much more violent than ablowout. The explosion can propel the tire, the rimcomponents, and the axle components as far as500 m (1500 ft) or more from the machine. Both theforce of the explosion and the flying debris can causeproperty damage, personal injury, or death.

21Safety Section

Electrical Storm Injury Prevention

g00337832Illustration 20(A) At least 15 m (50 ft)(B) At least 500 m (1500 ft)

Do not approach a warm tire. Maintain a minimumdistance, as shown. Stay outside the shaded area inIllustration 20.

Dry nitrogen gas is permitted for inflation of tires. Ifthe tires were originally inflated with air, nitrogen isstill permitted for adjusting the pressure. Nitrogenmixes properly with air.

Nitrogen inflated tires reduce the potential ofa tire explosion because nitrogen does not aidcombustion. Nitrogen helps to prevent oxidation ofthe rubber, deterioration of rubber, and corrosion ofrim components.

To avoid overinflation, proper nitrogen inflationequipment and training in the usage of the equipmentare necessary. A tire blowout or a rim failure canresult from improper equipment or from misusedequipment.

When you inflate a tire, stand behind the tread anduse a self-attaching chuck.

Servicing tires and rims can be dangerous. Onlytrained personnel that use proper tools and properprocedures should perform this maintenance. Ifcorrect procedures are not used for servicing tiresand rims, the assemblies could burst with explosiveforce. This explosive force can cause seriouspersonal injury or death. Carefully obey the specificinstructions from your tire dealer.

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Electrical Storm InjuryPreventionSMCS Code: 7000

When lightning is striking in the vicinity of themachine, the operator should never attempt thefollowing procedures:

• Mount the machine.

• Dismount the machine.

If you are in the operator’s station during an electricalstorm, stay in the operator’s station. If you are on theground during an electrical storm, stay away fromthe vicinity of the machine.

i01643597

Before Starting EngineSMCS Code: 1000; 7000

The steering frame lock must be in the unlockedposition in order to steer the machine.

Start the engine only from the operator compartment.Never short across the starter terminals or acrossthe batteries. Shorting could bypass the engineneutral start system. Shorting could also damage theelectrical system.

Inspect the condition of the seat belt and the conditionof mounting hardware. Replace any parts that areworn or damaged. Regardless of the appearance,replace the seat belt after three years of use.

Adjust the seat in order to have full pedal travel whenthe operator is seated properly.

Adjust the mirror so that the operator has goodrearward visibility.

Make sure that the machine is equipped with alighting system that is adequate for the job conditions.Make sure that all lights are working properly.

Before you start the engine or before you move themachine, make sure that no one is on the machine,underneath the machine, or around the machine.Make sure that there are no personnel in the area.

22Safety SectionEngine Starting

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Engine StartingSMCS Code: 1000; 7000


If a warning tag is attached to the engine start switchor to the controls, do not start the engine and do notmove any controls.

Move the hydraulic lockout control into the LOCKEDposition before you start the engine.

Engage the parking brake.

Diesel engine exhaust contains products ofcombustion which can be harmful to your health.Always operate the engine in a well ventilated area.If you are in an enclosed area, vent the exhaust tothe outside.

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Before OperationSMCS Code: 7000

Clear all personnel from the machine and from thearea. Maintain a distance of 91 m (300 ft) in alldirections prior to operation.

Clear all obstacles from the path of the machine.Beware of hazards such as wires, ditches, etc.

Make sure that all windows are clean. Secure thedoors in the shut position. Secure the windows in theshut position.

For the best vision of the area behind the machine,adjust the rear view mirror.

Make sure that the machine horn, the backup alarmand all other warning devices are working properly.

Fasten the seat belt securely.

i01390475

OperationSMCS Code: 7000

Only operate the machine while you are on the seat.The seat belt must be fastened while you operate themachine. Only operate the controls while the engineis running.

While you operate the machine slowly in an openarea, check for proper operation of all controls and allprotective devices.

Before moving the machine, ensure that no one willbe endangered.

Do not allow riders on the machine unless themachine has the following equipment:

• additional seat

• additional seat belt

Note any needed repairs during machine operation.Report any needed repairs.

Carry felling head approximately 40 cm (15 inches)above ground level. Do not go close to the edge of acliff, an excavation, or an overhang.

If the machine begins to sideslip downward on agrade, immediately remove the load and turn themachine downhill.

Avoid any conditions that can lead to tipping themachine. The machine can tip when you work onhills, on banks and on slopes. Also, the machinecan tip when you cross ditches, ridges or otherunexpected obstacles. Avoid operating the machineacross a slope.

Maintain control of the machine. Do not overload themachine beyond the machine capacity.

Be sure that the hitches and the towing devices areadequate.

Only connect the trailing equipment to a drawbar orto a hitch.

Never straddle a wire cable. Never allow otherpersonnel to straddle a wire cable.

Before you maneuver the machine, make sure thatno personnel are between the machine and thetrailing equipment. Block up the hitch of the trailingequipment in order to align the hitch with the drawbar.Maneuver the machine. Connect the machine to thetrailing equipment.

23Safety Section

Engine Stopping

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure(ROPS) installed during machine operation.

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Engine StoppingSMCS Code: 1000; 7000

NOTICEStopping the engine immediately after it has beenworking under load can result in overheating and ac-celerated wear of engine components.

Refer to the following procedure to allow the engineto cool and to prevent excessive temperatures in theturbocharger housing, which could cause oil cokingproblems.

1. Stop the machine and run the engine at low idlefor five minutes.

NOTICENever turn the battery disconnect switch to the OFFposition while the engine is running. Serious damageto the electrical system may result.

2. Turn the engine start switch to the OFF positionand remove the engine start switch key.

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Work ToolsSMCS Code: 6700

Only use work tools that are recommended byCaterpillar for use on Caterpillar machines.

If you are in doubt about the compatibility of aparticular work tool with your machine, consult yourCaterpillar dealer.

Make sure that all necessary guarding is in place onthe host machine and on the work tool.

Keep all windows and doors closed on the hostmachine. Always wear protective glasses. Alwayswear the protective equipment that is recommendedin the work tool’s operation manual. Wear any otherprotective equipment that is required for the operatingenvironment.

To prevent personnel from being struck by flyingobjects, ensure that all personnel are out of the workarea.

While you are performing any maintenance, anytesting, or any adjustments to the work tool stayclear of the following areas: cutting edges, pinchingsurfaces, and crushing surfaces.

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ParkingSMCS Code: 7000

1. Park the machine on a level surface. If you mustpark the machine on a downgrade, block the tiresor chock the tracks of the machine.

2. Apply the service brake in order to stop themachine. Move the direction control switch toNEUTRAL.

3. Engage the parking brake.

4. Lower all attachments to the ground. Make surethat all attachments are in the recommendedservicing position before servicing the machine.

5. Move the hydraulic lockout control to theLOCKED position. The hydraulic system remainspressurized provided that the accumulator ischarged. This condition is true even when theengine is not running. This pressure shoulddecrease in a short time (approximately oneminute). While the hydraulic system maintains acharge, the machine controls remain functional.

Deactivation of the hydraulic controls does notprevent the blade, boom swing, or auxiliary circuitfunctions from moving under gravity or other ex-ternal forces. Gravity or other external forces canmove the blade, boom swing, or auxiliary circuitfunctions suddenly if a hydraulic control lever ismoved.

Personal injury or death may occur from suddenmachine movement.

6. Turn the engine start switch to the OFF positionand remove the key.

7. Turn the battery disconnect switch to the OFFposition. If the machine will not be operated for anextended period of time, remove the key in orderto avoid battery discharge that may be causedby a battery short circuit, by the current draw viacertain components, or by vandalism.

24Safety SectionEquipment Lowering with Engine Stopped

Stay back until saw blade comes to complete stopafter shutdown.May cause serious injury or death.

g00894746Illustration 22The HF221 is shown in this graphic. Other models are similar.

8. Install the saw guard on the felling head.

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Equipment Lowering withEngine StoppedSMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipment ofall personnel. The procedure to use will vary withthe type of equipment to be lowered. Keep in mindmost systems use a high pressure fluid or air toraise or lower equipment. The procedure will causehigh pressure air, hydraulic, or some other mediato be released in order to lower the equipment.Wear appropriate personal protective equipment andfollow the established procedure in the Operationand Maintenance Manual, “Equipment Lowering withEngine Stopped” in the Operation Section of themanual.

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Sound Information andVibration InformationSMCS Code: 7000

The operator sound exposure Leq (equivalent soundpressure level) that is measured according to thework cycle procedures specified in “ANSI/SAEJ1166May90” is 86 dB(A). This measurement is forthe cab that is offered by Caterpillar, when the cab isproperly installed and maintained and tested with thedoors and the windows closed.

The operator sound pressure level measuredaccording to the procedures specified in “SAEJ919Apr95” is 79.5 dB(A). During this test, themachine was in high idle and the operator fan wasin the midrange position. This measurement is forthe cab that is offered by Caterpillar, when properlyinstalled and maintained and tested with the doorsand windows closed and with the machine in middlegear range and moving.

The exterior sound pressure level for the standardmachine measured at a distance of 15 m (49.2 ft)according to the test procedures specified in “SAEJ88Apr95”, with the machine in middle gear rangeand moving, is 81.5 dB(A).

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Operator StationSMCS Code: 7000

Any modifications to the inside of the operatorstation should not project into the operator space.The addition of a radio, fire extinguisher, and otherequipment must be installed so that the definedoperator space is maintained. Any item that is broughtinto the cab should not project into the definedoperator space. A lunch box or other loose itemsmust be secured. Objects must not pose an impacthazard in rough terrain or in the event of a rollover.

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